trinydex
01-09-2007, 01:24 PM
This downpipe is an HKS downpipe and will be put on to a 4G63. This is a general guide to installation of a downpipe, and might vary in hardware of other turbo motors.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2001.jpg
Tools you will need:
- 12mm, 14mm, and 17mm, 7/16in sockets w/ extentions and open/closed end wrenches.
- 7/16-20 nuts, washers, and bolts (which are at least 1 1/2" long.
- Some kind of breaker bar or pipe to use for extra leverage on the ratchet. i used the extension of the hydrolic jack as pictured below.
- downpipe gasket.
- 2 M8-1.25 nuts
- Here's a pic of the extra 7/16 nuts, bolts, and washer you should have before the installation.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2002.jpg
- And a pic of the extra M8-1.25 you will use to reinforce the hangar bolts.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2003.jpg
- Here's a pic of the extended handle I used off the jack.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2004.jpg
REMOVAL OF THE OLD INTAKE MANIFOLD
- Jack the car up and level up front and put jackstands for safety. The rear does not have to be up at this time since we won't be going that far back.
- Remove the 14mm bolts(x2) holding up the downpipe under the O2 housing which is under the turbo.
Left 14mm bolt before
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2005.jpg
Left 14mm bolt removed
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2006.jpg
- These are the 14mm bolts with springs removed.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2007.jpg
- Remove the 12mm bolts(x3) that hold up the first front lower tie bar. You do not have to remove the second front tie bar.
First 12mm bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2008.jpg
Second 12mm middle bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%200.jpg
Third 12mm bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2010.jpg
First front lower tie bar removed
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2011.jpg
- Separate the downpipe from the cat by unbolting the 17mm(x2) bolts and set aside the gasket.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2012.jpg
- The downpipe will now be loose and the only things holding it up are the hanagers. Remove the 12mm bolts(x2) holding it up. Don't loose the washers, as we'll use these again.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2013.jpg
- Be careful as the downpipe will now be loose and if your not supporting it with your hand IT WILL FALL ON YOU!
- Here's a pic of the undercarriage without the downpipe.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2014.jpg
- And a pic of the O2 housing that is under the turbo without the downpipe.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2015.jpg
- Set the downpipe aside and get ready to put on the new one. HKS downpipe on the left and the stock next to it with all the sheilds.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2016.jpg
INTALLATION OF THE DOWNPIPE
- Place the downpipe in the empty place of the old one.
- The downpipe hangers' nuts were welded on the bracket itself, so when you put it back on, you'll use the m8-1.25 nuts that you should have bought.
Pic of the welded nut on the bracket.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2017.jpg
Pic of the M8-1.25 nut on the hangar bolt.
- Bolt the 12mm hangar bracket bolts(x2) so that the downpipe will not fall, but don't tighten it just yet.
Here's a pic of it tightened, which you will do later.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2018.jpg
- Bolt the front part of the downpipe using 14mm bolts with spring to the O2 housing, but don't tighten them just yet.
Here's a pic of it tightened, which you will do later.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2019.jpg
- Insert the gasket between the Cat and the downpipe, but instead of the 17mm bolts(x2) we removed, use the 7/16 bolts, nuts, and washers to mate the two parts. Tighten.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2020.jpg
- Align and tighten the bolts with spring(x2) to the O2 housing.
- Align and tighten the 12mm bolts(x2) that secure the hangar brackets.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2021.jpg
- Now that the downpipe is secured, reinstall the lower tie bar with the remaining 12mm(x3) bolts that you should have.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2022.jpg
- Lower the car safely and start her up.
- Make sure there are no exhaust leaks. If there are, jack the car back up and make sure to tighten the bolts you might of missed, or did not tighten good enough.
- Enjoy your new down and watch out for cops, since this will make your exhaust note louder and is really for OFF ROAD USE ONLY!
- HKS!!!!
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2023.jpg
this is from the quoted author, i feel he did a great job and he filled an important void in our how to section and i'd like to tell socalevo that i really appreciate his effort (and a fine one it is)
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2001.jpg
Tools you will need:
- 12mm, 14mm, and 17mm, 7/16in sockets w/ extentions and open/closed end wrenches.
- 7/16-20 nuts, washers, and bolts (which are at least 1 1/2" long.
- Some kind of breaker bar or pipe to use for extra leverage on the ratchet. i used the extension of the hydrolic jack as pictured below.
- downpipe gasket.
- 2 M8-1.25 nuts
- Here's a pic of the extra 7/16 nuts, bolts, and washer you should have before the installation.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2002.jpg
- And a pic of the extra M8-1.25 you will use to reinforce the hangar bolts.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2003.jpg
- Here's a pic of the extended handle I used off the jack.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2004.jpg
REMOVAL OF THE OLD INTAKE MANIFOLD
- Jack the car up and level up front and put jackstands for safety. The rear does not have to be up at this time since we won't be going that far back.
- Remove the 14mm bolts(x2) holding up the downpipe under the O2 housing which is under the turbo.
Left 14mm bolt before
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2005.jpg
Left 14mm bolt removed
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2006.jpg
- These are the 14mm bolts with springs removed.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2007.jpg
- Remove the 12mm bolts(x3) that hold up the first front lower tie bar. You do not have to remove the second front tie bar.
First 12mm bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2008.jpg
Second 12mm middle bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%200.jpg
Third 12mm bolt
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2010.jpg
First front lower tie bar removed
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2011.jpg
- Separate the downpipe from the cat by unbolting the 17mm(x2) bolts and set aside the gasket.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2012.jpg
- The downpipe will now be loose and the only things holding it up are the hanagers. Remove the 12mm bolts(x2) holding it up. Don't loose the washers, as we'll use these again.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2013.jpg
- Be careful as the downpipe will now be loose and if your not supporting it with your hand IT WILL FALL ON YOU!
- Here's a pic of the undercarriage without the downpipe.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2014.jpg
- And a pic of the O2 housing that is under the turbo without the downpipe.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2015.jpg
- Set the downpipe aside and get ready to put on the new one. HKS downpipe on the left and the stock next to it with all the sheilds.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2016.jpg
INTALLATION OF THE DOWNPIPE
- Place the downpipe in the empty place of the old one.
- The downpipe hangers' nuts were welded on the bracket itself, so when you put it back on, you'll use the m8-1.25 nuts that you should have bought.
Pic of the welded nut on the bracket.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2017.jpg
Pic of the M8-1.25 nut on the hangar bolt.
- Bolt the 12mm hangar bracket bolts(x2) so that the downpipe will not fall, but don't tighten it just yet.
Here's a pic of it tightened, which you will do later.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2018.jpg
- Bolt the front part of the downpipe using 14mm bolts with spring to the O2 housing, but don't tighten them just yet.
Here's a pic of it tightened, which you will do later.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2019.jpg
- Insert the gasket between the Cat and the downpipe, but instead of the 17mm bolts(x2) we removed, use the 7/16 bolts, nuts, and washers to mate the two parts. Tighten.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2020.jpg
- Align and tighten the bolts with spring(x2) to the O2 housing.
- Align and tighten the 12mm bolts(x2) that secure the hangar brackets.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2021.jpg
- Now that the downpipe is secured, reinstall the lower tie bar with the remaining 12mm(x3) bolts that you should have.
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2022.jpg
- Lower the car safely and start her up.
- Make sure there are no exhaust leaks. If there are, jack the car back up and make sure to tighten the bolts you might of missed, or did not tighten good enough.
- Enjoy your new down and watch out for cops, since this will make your exhaust note louder and is really for OFF ROAD USE ONLY!
- HKS!!!!
http://www.socalevo.net/gallery/albums/userpics/10991/INSTALL%20downpipe%20%28hks%29%2023.jpg
this is from the quoted author, i feel he did a great job and he filled an important void in our how to section and i'd like to tell socalevo that i really appreciate his effort (and a fine one it is)